Download DVL EF Insert Owner`s Manual
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DVL EF Insert Owner's Manual Featuring the Burner Tested and Listed by OMNI-Test Laboratories, Inc. Beaverton, Oregon ANSIZ21.88 1998 CSA 2.33 M98 CAN/CGA 2.17 M81,U.L.307b • Direct Vent Fireplace Insert • Masonry or Factory Built (Metal) Fireplace • Residential or Mobile Home WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency, or the gas supplier. - Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. - Installation must be performed by a qualified installer, service agency or the gas supplier IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. Installer: After installation give this manual to the home-owner and explain operation of this heater. Copyright 2005, Travis Industries, Inc. $10.00 100-01151 Travis Industries, Inc. 4800 Harbour Pointe Blvd. SW Mukilteo, WA 98275 Introduction 2 Introduction We welcome you as a new owner of a Travis DVL Insert. In purchasing a Travis DVL Insert you have joined the growing ranks of concerned individuals whose selection of an energy system reflects both a concern for the environment and aesthetics. The Travis DVL Insert is one of the finest home heaters the world over. This manual will explain the installation, operation, and maintenance of this heater. Please familiarize yourself with the Owner's Manual before operating your heater and save the manual for future reference. Included are helpful hints and suggestions that will make the operation and maintenance of your new heater an easier and more enjoyable experience. We offer our continual support and guidance to help you achieve the maximum benefit and enjoyment from your heater. Important Information No other Travis DVL Insert has the same serial number as yours. The serial number is below and to the left of the gas control valve. This serial number will be needed in case you require service of any type. Model: Travis DVL Insert EF Serial Number: Purchase Date: To receive full warranty coverage, you will need to show evidence of the date you purchased your heater. Do not mail your Bill of Sale to us. We suggest that you attach your Bill of Sale to this page so that you will have all the information you need in one place should the need for service or information occur. Purchased From: Travis Industries Mail your Warranty Card Today, and Save Your Bill of Sale. 4041028 100-01151 Table of Contents Introduction & Important Info. 3 Operating Your Heater Introduction & Important Information.........................2 Before You Begin ..................................................22 Location of Controls ..............................................22 Starting The Pilot Flame..........................................23 Starting the Heater for the First Time .........................24 Turning the Heater On and Off .................................24 Adjusting the Flame Height......................................24 Adjusting the Blower Speed.....................................25 Normal Operating Sounds .......................................25 Normal Operating Odors .........................................25 Safety Precautions Safety Precautions ...............................................4 Features & Specifications Installation Options ...............................................6 Heating Specifications ...........................................6 Dimensions..........................................................6 Fuel....................................................................6 Compliance..........................................................6 Maintaining Your Heater Maintaining Your Heater's Appearance ......................26 Cleaning Your Heater .............................................26 Yearly Service Procedure .......................................26 Troubleshooting Table............................................27 How this Stove Works ............................................28 Wiring Diagram .....................................................29 Replacement Parts List ..........................................29 Insert Installation Installation Warning...............................................7 Items Required for Installation .................................7 Packing List.........................................................7 Items Packed with Face .........................................7 Order of Installation...............................................7 Insert Placement ..................................................8 Zero Clearance (Metal) Fireplace Requirements...........8 Hearth Requirements .............................................8 Insert Clearances .................................................9 Mantel Requirements .............................................9 Face Sizing..........................................................9 Gas Line Installation..............................................10 Vent Requirements................................................11 Altitude Considerations ..........................................11 Vent Installation ...................................................11 Vent Location.......................................................12 Vent Configurations...............................................13 Installation Without Surround Panels ........................14 Surround Panel Installation .....................................15 Manifold Removal and Installation ............................16 Listing Information Safety Label ........................................................30 Warranty Warranty .............................................................31 Optional Equipment LP Conversion Instructions.....................................32 Cast Aluminum Firebacks .......................................34 Ceramic Firebacks ................................................36 Index Index..................................................................38 Finalizing the Installation Glass Removal .....................................................17 Log, Twig, and Ember Installation .............................19 Purge and Leak Test the Gas Line ............................20 Pilot Flame Inspection............................................20 Air Shutter Adjustment ...........................................21 Flame Inspection ..................................................21 Explain Heater Operation to Owner ...........................21 Travis Industries 4041028 100-01151 Safety Precautions 4 • IF YOU SMELL GAS: * * * * * Do not light any appliance Extinguish any open flame Do not touch any electrical switch or plug or unplug anything Open windows and vacate building Call gas supplier from neighbor's house, if not reached, call fire department • This unit must be installed by a qualified installer to prevent the possibility of an explosion. Your dealer will know the requirements in your area and can inform you of those people considered qualified. The room heater should be inspected before use and at least annually by a qualified service person. More frequent cleaning may be required due to excessive lint from carpeting, bedding material, etc. • The instructions in this manual must be strictly adhered to. Do not use makeshift methods or compromise in the installation. Improper installation will void the warranty and safety listing. Look for this label: • For LPG only | Pout 11” W.C. If the label is present, the heater is equipped for LP (propane). If the label is absent, the heater is equipped for NG (natural gas). • Contact your local building officials to obtain a permit and information on any installation restrictions or inspection requirements in your area. Notify your insurance company of this heater as well. • If the flame becomes sooty, dark orange in color, or extremely tall, do not operate the heater. Call your dealer and arrange for proper servicing. • It is imperative that control compartments, screens, or circulating air passageways of the heater be kept clean and free of obstructions. These areas provide the air necessary for safe operation. • Do not operate the heater if it is not operating properly in any fashion or if you are uncertain. Call your dealer for a full explanation of your heater and what to expect. Ok • Gas Travis Industries This heater is either approved for natural gas (NG) or for propane (LP). Burning the incorrect fuel will void the warranty and safety listing and may cause an extreme safety hazard. Direct questions about the type of fuel used to your dealer. Check the label and flame adjust knob on the gas control valve. ? Do not store or use gasoline or other flammable liquids in the vicinity of this heater. AAAAA AA AAAAA AA AAAAA 4041028 • Do not operate if any portion of the heater was submerged in water or if any corrosion occurs. 100-01151 Safety Precautions • AA AA Travis Industries AA AA AA AA A Do not place clothing or other flammable items on or near the heater. Because this heater can be controlled by a thermostat there is a possibility of the heater turning on and igniting any items placed on or near it. • The viewing glass should be opened only for lighting the pilot or conducting service. • Any safety screen or guard removed for servicing must be replaced prior to operating the heater. • Operate the heater according to the instructions included in this manual. • If the main burners do not start correctly turn the gas off at the gas control valve and call your dealer for service. • This unit is not for use with solid fuel • Do not place anything inside the firebox (except the included fiber logs). • If the fiber logs become damaged, replace with Travis Industries log set. • Children and adults should be alerted to the hazards of high surface temperature and should stay away to avoid burns or clothing ignition. Young children should be supervised when they are in the same room as the heater. • 5 Instruct everyone in the house how to shut gas off to the appliance and at the gas main shutoff valve. The gas main shutoff valve is usually next to the gas meter or propane tank and requires a wrench to shut off. 4041028 • Light the heater using the built-in piezo igniter. Do not use matches or any other external device to light your heater. • Never remove, replace, modify or substitute any part of the heater unless instructions are given in this manual. All other work must be done by a trained technician. Don't modify or replace orifices. • Allow the heater to cool before carrying out any maintenance or cleaning. • The pilot flame must contact the thermopile and thermocouple (see the illustration to the left). If it does not, turn the gas control valve to "OFF" and call your dealer. • Do not throw this manual away. This manual has important operating and maintenance instructions that you will need at a later time. Always follow the instructions in this manual. This Manual • Plug the heater into a 120V grounded electrical outlet. Do not remove the grounding plug. • Don’t route the electrical cord in front of, over, or under the heater • Travis Industries, Inc. grants no warranty, implied or stated, for the installation or maintenance of your heater, and assumes no responsibility of any consequential damage(s). 100-01151 Installation 6 (for qualified installers only) Features: - Works During Power Outages (millivolt system) - High Efficiency - Optional Thermostat or Remote Control - Ember Fyre™ Burner for "Wood Fire" Look - Quiet Blower for Effective Heat Distribution - Convenient Operating Controls - Variable-Rate Heat Output - Low Maintenance Heating Specifications: Approximate Heating Capacity (in square feet)* BTU Input Per Hour (on high) BTU Output on Low Efficiency** (with blowers on) AFUE (Annual Fuel Utilization Efficiency) * Installation Options: - Residential or Mobile Home - Fireplace Insert - Masonry or Zero Clearance (Metal) Fireplace Natural Gas 600 to 2,000 40,000 20,700 78.9 % 71.0 % Propane 600 to 2,000 40,000 17,900 81.0 % 73.7 % Heating capacity will vary with floor plan, insulation, use of power heat vent, and outside temperature. ** Efficiency rating is a product thermal efficiency rating determined under continuous operation independent of installed system. See the section "Vent Requirements" for vent location. 23-3/4" 33-3/8"* 8x10 Arch/Rect. Panels 36-3/8"* 10x13 Rect. Panels 32-1/4" 17-3/8" 44-3/16"* 8x10 Arch/Rect. Panels 48-3/16"* 10x13 Rect. Panels * Includes trim & standoffs 16"* 1-5/8"* Fuel: This heater is designed either for natural gas or for propane. Check the sticker on top of the gas control valve or check with the installer to verify gas use. Compliance: This unit has passed the ANSI Z21.88 – 1998, CSA 2.33 M98 Vented Gas Fireplace Heater Standard as tested by OMNI-Test Laboratories, Inc. Beaverton, Oregon. Travis Industries 4041028 100-01151 Installation 7 (for qualified installers only) Installation Warnings: ! ! ! ! ! ! ! ! Failure to follow all of the requirements may result in property damage, bodily injury, or even death. This heater must be installed by a qualified installer who has gone through a training program for the installation of direct vent gas appliances. This appliance must be installed in accordance with all local codes, if any; if not, follow ANSI Z223.1 and NFPA 54(88) in the USA and B-149 in Canada. In Manufactured or Mobile Homes must confirm with: In USA, Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280; In Canada, CSA Z240.4 and Gas-Equipped Recreational Vehicles and Mobile Housing. This appliance may be installed in Manufactured Housing only after the home is site located. The DVL Insert is designed to operate on natural gas (NG) or propane (LP). All exhaust gases must be vented outside the structure of the living-area. Combustion air is drawn from outside the living-area structure. Notify your insurance company before hooking up this heater. The requirements listed below are divided into sections. All requirements must be met simultaneously. The order of installation is not rigid – the qualified installer should follow the procedure best suited for the installation. Additional Items Required for Installation • • • • • • 6-5/8” to 3” & 4” Co-Linear Adapter – W/ Flashing (Travis Part # 98900124) Face Gas Hookup Equipment Surround Panels (Optional - see “Installation without Surround Panels”) 3” and 4” Diameter Gas Liner Direct Vent Cap (Simpson Duravent Part # 991) Packing List • DVL Insert • Log Set (Log Set, Coals, and Embers) • Owner's Manual • Two Leveling Bolts • Propane Conversion Kit • "Fireplace Altered" tag (attach to the fireplace) • 8" Pipe Inlet (3/8" dia.) • Door Latch Key • Block Off Plate • (2) Fireback Clips (for ceramic firebacks only) Items Packed with the Face • Face (with attachment hardware) • Face Installation Instructions Order of Installation 1 2 3 4 5 6 If the heater is to use propane, install the propane conversion kit (see page 32) Install gas line into the fireplace (do not connect to unit) Position the heater (see "Insert Placement") Connect the gas line and gas vent to the appliance. Install the optional surround panels and trim. Attach the on/off switch. Follow the instructions under "Finalizing the Installation" on pages 17 through 21. Travis Industries 4041028 100-01151 Installation 8 (for qualified installers only) Insert Placement • Insert must be placed within a code-conforming masonry fireplace or tested and listed zero-clearance (metal) fireplace. Fix any fireplace damage prior to installation. • Because the insert uses a circulation blower, clean the fireplace, smoke shelf, and chimney prior to installation. We recommend painting the interior surface of the fireplace with latex paint to further eliminate dust. • This heater may be placed in a bedroom. Please be aware of the large amount of heat this appliance produces when determining a location. For tight fits (under 28"), you may remove the manifold. See the section "Removing the Manifold" Min. 38-1/4" - Includes 6" for gas line installation Attach the "This fireplace has been altered..." plate to the fireplace (use two screws or other suitable method). You may wish to place it in a location Min. 23-3/4" where it will be covered by the surround panels. The DVL inserts 16" into the fireplace. Use the leveling bolts for fireplaces with recessed floors. The gas line and shutoff Run the power cord to either valve should be installed side of the insert along the face. prior to insert placement. Run the on/off switch wires to the right, behind the surround panels. Zero-Clearance (Metal) Fireplace Requirements: AA AAA AAAAA AA AA AAAAAAAAA AA • The damper ("A") and grate (with log set) ("B") must be removed (see the illustration below) • The smoke shelf ("C"), internal baffles ("D"), screen ("E"), masonry lining or refractory ("G" & "I"), and metal or glass doors ("F") may be removed (if applicable) NOTE: • If any internal baffle is cut, bent, or removed, the fireplace must be permanently marked to indicate that it has been altered and is no longer suitable for burning solid fuel (wood). The insulation ("H"), and any structured rigid frame members (metal sides, floor, door frame, face of the fireplace, etc.) must not be removed or altered. H F A C D I E B G Hearth Requirements • The heater must be installed on a non-combustible hearth extending a minimum 12" from the fireplace opening (local codes may require a larger hearth). The hearth must also extend to both sides of the face (see page 9 for face sizing). Travis Industries 4041028 100-01151 Installation 9 (for qualified installers only) Insert Clearances • Due to the high temperature of the fireplace, it should be located out of traffic and away from furniture and draperies. AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA Co u mb Co Max. 8” mb stib u le le stib or n No To pF -C a om bu stib le Ma nte l Side Wall g cin Min. 10” Min. 8-1/2” See “Face Sizing” Below Min. 6” Side Facing The non-combustible hearth must be as wide as the face and extend to both sides. See “Face Sizing” Below Min. 6” 12” Min. (from fireplace opening) Mantel Clearances The mantel must be a minimum 10” above the face and a maximum 8” deep. NOTE: The combustible area above the facing must not protrude more than 3/4" from the facing. If it does, it is considered a mantel and must meet the mantel requirements listed in this manual. Face Sizing AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA 2-3/8” Avalon Rosario DVL Avalon Rawhide Avalon Craftsman Cambridge DVL Avalon 2-1/4” Avalon Victorian DVL 37-5/8” 27-1/2” 27-1/2” 27” 16-1/2” 26” 35-3/4” 35-3/4” 35-3/4” 36-3/4” 25-7/8” 36” * The decorative braces protrude 1/4” 2” Lopi Discovery DVL FPX 34 Rectangular Bevel FPX Arched FPX Artisan NOTE: Artisan faces vary in size. FPX 34 Architectural Faces 3-1/2" Radius = 45” 26” 35-3/4” 26-1/2” 34-3/4” Travis Industries Access Door 27-7/8” 26-1/2” 34-3/4” 4041028 Access Door Access Door 33-5/8” 100-01151 27” Installation 10 (for qualified installers only) Gas Line Installation ! This appliance must be installed in accordance with all local codes, if any; if not, follow ANSI Z223.1 and NFPA 54(88) in the USA and B-149 in Canada. ! The heater and gas control valve must be disconnected from the gas supply piping during any pressure testing of that system at test pressures in excess of 1/2 psig (3.45 kPA). For pressures under 1/2 psig (3.45 kPA), isolate the gas supply piping by closing the manual shutoff valve. • Leak test all gas line joints and the gas control valve prior to and after starting the heater. Gas Line Connection • The location of the gas inlet is shown below • A manual shutoff valve is required within 3’ of the fireplace. It should be placed upstream of the flex line (if used) and may be installed behind the access door inside the heater. ). THandle gas cocks are required in Massachusetts in compliance with code 248CMR. A 6" wide opening is provided on the left side, 3" behind the fireplace opening. It is 3" tall. Shutoff Valve The gas inlet on the gas control valve is located 3-5/8" behind the fireplace opening, 7-3/4" to the left of the center, and 1-7/8" above the base of the appliance. Apply thread sealant to both ends of the pipe prior to installation. With the 8" pipe nipple installed, the inlet is approximately 15" from the center of the appliance. Shutoff Valve Gas Control Valve 8" Gas Inlet Pipe (shipped with the insert in the accessory pack) Fuel • This heater is designed for natural gas but can be converted to propane. Check the sticker on the top of the gas control valve to make sure the correct fuel is used. Gas Inlet Pressure Standard Input Pressure Natural Gas 7" W.C. (1.74 kPA) Propane 13" W.C. (2.73 kPA) • If the pressure is not sufficient, make sure the piping used is large enough and the total gas load for the residence does not exceed the amount supplied. • The supply regulator (the regulator that attaches directly to the residence inlet or to the propane tank) should supply gas at the suggested input pressure listed above. Contact the local gas supplier if the regulator is at an improper pressure. Travis Industries 4041028 100-01151 Installation 11 (for qualified installers only) Vent Requirements ! The gas appliance and vent system must be vented directly to the outside of the building, and never be attached to a chimney serving a separate solid fuel or gas-burning appliance. Each direct vent gas appliance must use it's own separate vent system. ! Make sure the exhaust pipe on the heater connects to the exhaust portion of the cap. The illustrations below show how the flex liners should be attached. • The exhaust vent must reline the entire length of the chimney and terminate above the chimney top ! Be careful not to crimp or rupture the liner when bending it into chimney offsets • When installed, the vent must meet all of the vent manufacturer's requirements • Make sure to order the following: - 4” UL 441 Gas Liner for Exhaust, 3” UL 441 Gas Liner for Air Inlet - 6-5/8” to 3” & 4” Co-Linear Adapter & Flashing (Travis Part # 98900124). - Vertical Termination Cap (Dura-Vent pt # 991) Exhaust (4" dia.) Max. Ht. 35' Min. Ht. 8' Altitude Considerations This heater has been tested at altitudes ranging from sea level to 8,000 feet (2,400 M). In this testing we have found that the heater, with its standard orifice, burns correctly with just an air shutter adjustment. If local codes require resizing the orifice, in the U.S.A. refer to ANSI 223.1, Appendix P, in Canada B-149.1 or B-149.2 ! AA AA AA AA AA AA AA Max. 1' offset Failure to adjust the air shutter properly may lead to improper combustion which can create a safety hazard. Consult your dealer or installer if you suspect an improperly adjusted air shutter. 1/4" Nutdriver Vent Restrictor WARNING: Restrictor adjustment should only be done by a qualified installer. Only those installations determined to be over-drafting require this adjustment. The best indication of over-drafting is a hyper-active flame pattern (flames that move too quickly). If the air shutter is constricted, the flames become short and yellow, yet still very active. Over-drafting may affect the pilot, but this is not the best way to determine over-drafting. Overdrafting is most likely in tall venting configurations (especially if using an “Exhaust Only Re-Line”). Do not over-restrict the vent (this leads to ghosting or lifting flames - reduce restrictor setting). Travis Industries Inlet (3" dia.) Screw Rotate the adjustment plate to change the restrictor position. 6 5 7 Index Holes 8 9 10 11 4 3 21 Adjustment Plate Pivot Point This restrictor is in Position #3. NOTE: Position #1 is the fully open position To Adjust the Restrictor: 1 2 3 4 Determine a restrictor position. Start low(move the restrictor a maximum two positions at a time) and thoroughly test the heater before adjusting further. Remove the screw with a 1/4" nutdriver (or screwdriver). Rotate the adjustment plate clockwise until the correct index hole is below the pivot point. Insert the screw into the correct index hole and tighten. 4041028 100-01151 12 Installation (for qualified installers only) Vent Installation Exhaust (4”) Apply high-temperature silicone to the liners on both ends and secure with 2 screws. Inlet (3”) 4” dia. Gas Liner Termination Cap (Simpson Part # 991) 3” dia. Gas Liner p. High-Tem Silicone 6-5/8” to 3” & 4” CoLinear Adapter (Travis Part # 98900124) Hig h-T Silic emp. one Inlet Exhaust Center Line Vent Location Inlet (3” Dia.) Exhaust (4” Dia.) 2-1/4” 13-7/8” 2” 13-1/4” Vent Configurations Fireplace Opening 16” Inlet & Exhaust Re-Line Direct Vent Cap (part # 991) Exhaust 4" dia. Gas Liner AAA AA A AA A AA A AA A AA A AAA AAA AA A AAA AA A AAA AA A AAA AAA AA AA Exhaust Only Re-Line (recommended) AAA A AA AAA A AA AAAAA AAA AA AAAA AAA A AA AAAA A AA AAA A AAA AAAAA A AAA AA AAA AA AAAAA AA AA A AAA AAAAA AAA AA A AAAAAAAAA AAAAA 6-5/8" to 3" & 4" Colinear Adapter & Flashing (Travis Part # 98900124) Inlet 3" dia. Gas Liner Recommended Block-Off Plate (non-combustible metal and/or insulation). Prevents odors from chimney entering room. Suggestion: Paint the fireplace cavity with latex paint to eliminate the possibility of odors from the fireplace circulating into the room. Z.C. (Metal) firebox Exhaust 4" dia. Gas Liner Any cracks or damage inside the chimney must be repaired. The block-off plate mus seal the intake to the chimney space. This way air is drawn down the chimney for combustion air. Block-Off Plate (non-combustible materials) Inlet Masonry Fireplace NOTE: You may use either re-line configuration with a masonry or zero-clearance fireplace. Travis Industries 4041028 100-01151 Installation 13 (for qualified installers only) Installation Without Surround Panels The insert may be installed without surround panels if a 3/8" gap is allowed between the sides and top of the face and the fireplace (for ventiliation). Wire mesh screen may be placed over this gap. a Min. 3/8" b Face Dimensions See “Face Sizing” on page 9. Use a knife to cut out the on/off switch hole (the label covers a square hole in the bracket). c Use a lock tie or other device to bundle the excess wire. Then tuck it below the piezo igniter to keep it from coming in contact with the burner pan. Disconnect the on/off switch from the red and brown wires. Insert the switch into the hole until it locks in place. Re-attach the red and brown wires (orientation does not matter). AA AA Keep the jumper wire in place while installing. Surround Panel Installation PANEL SIZE 8" x 10" Rectangular Arched (8” x 10”) 10” x 13” Rectangular WIDTH 44-3/16" 44-3/16" 48-3/16" HEIGHT 33-3/8" 33-3/8" 36-3/8" a 1 Follow the instructions to the right for installing the side panels. Pre-thread the holes on the surround panels with the screws included in the surround panel kit. 5/16" Nutdriver Run the wires from the on/off switch and the power cord behind the surround panel (cut the locktie holding the on/off switch in place). b Line up each side surround panel and insert two screws from the inside to secure in place. Travis Industries 4041028 100-01151 Installation 14 (for qualified installers only) Surround Panel Installation (continued) 2 Follow the instructions below for installing the top panel, insulation, and trim. AAAAAAAAAAAA AAAAAAAAAAAA AAAAAAAAAAAA AA AAAAAAAAAAAA AA AAAAAAAAAAAA Top Trim NOTE: On arched panels make sure these stand-offs are perpendicular and not bent b Top Panel A A over or flattened. a "L" Bracket Slot for on/off switch (rectangular or arched) c Tighten the set screws from the back side with a small standard screwdriver Top Trim "L" Bracket Right Side Trim Right Side Trim Install the top panel so the two tabs insert into the slots on the side panels. 3 WARNING: The insulation must be installed along the top of the insert and should cover or be below the rheostat (to protect it from heat). Failure to install the insulation will invalidate facing and mantel clearances, creating a fire hazard. Tuck the included insulation between the top panel and the facing below the rheostat (not along the sides). Cut off excess insulation. Double-Back Tape Construct the panel trim. Insert one leg of each "L" bracket into the top and side trim piece. Align the trim to form a precise corner, then tighten the two set screws with a small standard screwdriver. Slide the trim over the panels. Attach a piece of included doubleback tape to the bottom of each side trim to keep it from flaring at the bottom. Install the on/off switch following the directions below. Upper Right of Trim Disconnect the on/off switch from the red and brown wires leading from the heater. Insert the switch into the hole in the upper right of the panel trim until it locks in place. Re-attach the red and brown wires (orientation does not matter). AA AA AA AAA AA AA AA AAAA Keep the jumper wire in place while installing. Travis Industries 4041028 100-01151 Installation 15 (for qualified installers only) Manifold Removal and Installation • The manifold is shipped attached to the insert, but may be removed to facilitate especially tight installations. See the directions below for installation. 1 Remove the manifold and place it within the fireplace (see the instructions on the following page). 2 Route the flex vent through the chimney from above (leave an extra 3' (914 mm) at the top). 3 Attach the flex vent to the manifold (seal with silicone and attach with screws). 4 Place the manifold in an upright position (so it rests on the manifold legs) and have a partner pull on the excess flex vent. Temporarily attach the flex vent to the top of the chimney (leave extra slack). 5 Slide the insert into place, guiding the convection top over the insert until fully in place. 6 After removing any slack from the flex vent, attach the manifold to the appliance. AA AAA AAA AAA AA AA AAA AAA AA AAA AA AA A A AA AA AAA AA AA AA A A AAA AA AA AAA AA AA AA A A AAA AA AA AAA AA AAA A A AA AA AA AA AA A AA AAA AA AAA AAAA AA A A A AA AA AA AAA AA AA AA AA AAA AA A AA AA AA A A AA AA AAA AA AA AA AA AAA AA AA AA A A AA AA AAA AA AA AAA AAAAAA AAAA AA AA A AA AA A AAA AAA AA AA AA AA A A AAA AA AA A AA AAA AA AAA AAAA AAAAA A AA AA AA AA A A AA AA AA AA AA A A A AAA AA AA A AA AA AA AA A A AA A AA A A AAA AA AAAAAA AA AAAA A AAA AAAAA AA AAAAAA AAAAA 7 Remove any excess slack in the flex line then attach the vent termination. 2 4 1 3 4 Travis Industries 4041028 AAA AA A AAA AA A AAAA AA AAAA AA AA AAA AAAA A AAA AA AA AA A AAA AA AA A AAA AAA AAA AAAA AAA AAAAA AA A AAA AA A AAAA AAAAAAA AAA 7 6 5 100-01151 Installation 16 (for qualified installers only) Manifold Removal and Installation (Continued) Remove the glass (see the instructions on page 17). Follow the directions below to remove the manifold. N O T E : When replacing the manifold, use the convection top to guide the manifold. You may also reach through the exhaust ducts to guide the manifold forward to the appropriate location. Convection Top Manifold 5/16" Nutdriver Remove the three screws holding the convection top to the insert. Slide the manifold back. Remove the four bolts inside the firebox. 7/16” Socket Shim the manifold legs if installing into a fireplace with a raised hearth. NOTE: when installing the manifold, make sure the gaskets sealing the inlet and exhaust ducts are in place. If a gasket is loose, use hightemperature silicone to secure it to the manifold. Electrical Connection • Plug the power cord into a grounded 120 Volt outlet (do not remove the grounding pin). Travis Industries 4041028 100-01151 Finalizing the Installation 1 17 Remove the glass following the directions below. Warning: The appliance must be completely cool before removing the glass. Warning: Do not strike or slam the glass. Note: a If using an Victorian Lace face, attach the arch covers after installing the glass. Spring Pin Open the four latches holding the glass Insert the 1/4” key into the spring frame in place (start with the two below Top of Firebox the glass) - follow the directions shown pin. to the right. Glass Twist 1/4 turn. Glass Frame b Lift the glass frame up and pull it forward to NOTE: You may need to lift the glass frame while re-attaching. remove. Latch Bracket The spring pin will disengage from the latch bracket, opening the latch. Re-Attaching the Glass Frame: a) Hang the glass frame on the firebox. b) While holding in place, attach the upper latches (follow the instructions to the right in reverse). c) Lift the glass frame slightly and attach the lower latches. Travis Industries 4041028 100-01151 Finalizing the Installation 18 Glass Frame Removal and Installation (continued) The spring pin can come loose from the latch assembly. This occurs when it is turned 1/4 turn when it is disengaged. Follow the directions below to re-install the spring pin if it becomes loose. To re-install the spring pin, first insert this end into a 1/4” key. NOTE: The spring pins can be installed with the glass frame in place or removed. Insert the spring pin into this bracket with the pins aligned vertically. Push in slightly and twist 1/4 turn. With this pin horizontal, the spring pin will remain in place. Travis Industries 4041028 100-01151 Finalizing the Installation 19 • If converting this unit to propane, do so now (see the instructions on page 32). 2 Install the log set, kibbles (optional), and embers (if using the decorative fireback, install it prior to the log set - page 36). a Place the rear log on the two platforms at the rear of the firebox. AA AA AA AA AA AAAAAA AA AA AA These pins insert into the holes in the log. AA AA AA AA AA AA AA AA AA AA b Place the left and right logs. The pins on the burner insert into the holes on the logs. c Place the twig over the rear log. The pins on the log insert into the holes on the twig. AA AAA AAA d On newer untis, an ember chunk is included with the heater (instead of cast into the burner). Place it in the location shown (it should not cover any burner holes). e Travis Industries Place the embers over the front and side edges of the burner (do not place them over the burner holes). Place them in a random pattern. 4041028 100-01151 Finalizing the Installation 20 ! We recommend you purge the gas line at this time (with the glass removed). This allows gas to be detected once it enters the firebox, ensuring gas does not build up. 3 Turn on gas to the heater. Leak test all gas joints prior to starting the appliance. Start the pilot (see page 23). Warning: When lighting or re-lighting the pilot, the glass must be removed (see page 23 for the full set of instructions on starting the pilot). 4 Replace the glass (see page 17). Start the main burner. Leak test all gas joints again. 5 Install the faceplate following the instructions included with the face (shut off the insert if necessary). ! ACID WASH WARNING: Before installing the faceplate, make sure any masonry that has been treated with acid wash has been properly neutralized (this is used primarily with brick faces). Acid wash (muriatic acid) is used to remove excess mortar. If not properly neutralized with an ammonia solution, the gold or nickel face may develop a permanent tarnish when the acid evaporates over time. Contact your dealer if uncertain your facing has been properly neutralized. 6 Check the pilot flame to make sure it looks like the illustration below. Adjust the pilot flame if necessary. The pilot flame must contact the thermocouple and To adjust the pilot flame, turn this screw. Clockwise thermopile (see the illustration below). Adjust the pilot up or lowers the flame while counter-clockwise raises it. Standard Screwdriver Travis Industries 4041028 down as necessary. 100-01151 Finalizing the Installation 21 7 Let the heater burn for fifteen minutes. Adjust the air shutter, if necessary, to achieve the correct looking flame (see the illustration below). • The air shutter adjusts the amount of air that mixes with the gas before it exits the burner holes. It is used to fine-tune the flame for differences in altitude and vent configuration. There are two air shutters on this fireplace - adjust both air shutters to obtain the correct flame. Rear Air Shutter Control Move the controls left or right until the flame looks correct. The rear air shutter affects the rear portion of the burner, the front air shutter the front portion of the burner. Pushing to the right gives the flame less air (making it more orange). Pushing to the left gives the flame more air, making it more blue. Front Air Shutter Control NOTE: If the air control is all the way open, yet the flames remain sooty, shut off gas to the fireplace and contact a qualified gas service technician. NOTE: The logs must be installed correctly to monitor the flame while adjusting the air shutter. Correct Not Enough Air Too Much Air Flames should be blue at the base, yellow-orange on the top. If the flames are over 14" tall or sooty on the ends, open the air shutter. If the flames are all blue and short, close the air shutter. ! If the air shutter is in its fully open position, yet the flames remain sooty, shut off gas to the heater and contact the Travis Dealer for instructions. ! If the vent configuration is installed incorrectly the vent may cause the flames inside the heater to lift or "ghost" – a dangerous situation. Inspect the flames after installation to insure proper performance. If the vent configuration is correct, yet the flames are lifting or ghosting, shut off gas to the heater and contact the dealer for information on remedying the problem. ! This heater has been tested at altitudes up to 8,000 feet. In this testing we have found that the heater, with its standard orifice, burns correctly with just an air shutter adjustment. ! Failure to properly adjust the air shutter may lead to improper combustion and a safety hazard. Consult your dealer if you suspect an improperly adjusted air shutter. Burner Pan The flames should burn right off the top of the burner ports (if they are too blue, adjust the air control). Burner Ports (holes) If the flames are lifting, yet the vent configuration is correct, contact your dealer. If the flames are ghosting, yet the vent configuration is correct, contact your dealer. 8 Turn the flame adjust knob to its highest position - the flames should be approximately 12" tall. Check the flame on low position. The flames should burn off of each burner hole. If the heater does not work correctly, contact the Travis Dealer for instructions. 9 Give this manual to the home owner and fully explain the operation of this heater. Travis Industries 4041028 100-01151 Operation 22 Before You Begin ! Read this entire manual before you use your new heater (especially the section "Safety Precautions" on pages 4 & 5). Failure to follow the instructions may result in property damage, bodily injury, or even death. Location of Controls - See explanation below The Pilot Flame can be found below the back log. An instruction card for operating the fireplace is attached to the inside of the fireplace here. Replace it for easy reference. AA AA AA AA PILOT IGNITER OF F ON/OFF Switch The on/off switch is located on the upper right corner of the surround panels. Open the access door to view the controls. Gas Control Valve ON OFF HI LO BLOWER CONTROL Gas Control Knob Flame Adjust Knob Pilot Igniter Blower Knob Blower Knob This knob controls the speed of the internal convection blower that pushes the heated air into the room. On/Off Switch This control is used to turn the heater on and off. Pilot Igniter The pilot igniter is used only to start the pilot. When pressed, it sends an electrical charge to the pilot assembly. This creates a blue spark directly next to the pilot, igniting the pilot flame. Gas Control Knob This knob is used to control gas to the heater and for starting the pilot. There are three positions, ON, OFF, & PILOT. The pointer directly below the knob indicates the position this knob is in. Flame Adjust Knob This knob controls the flame height from low ("LO") to high ("HI"). The pointer to the upper left of the knob points to the position this knob is in. • If using a remote control or thermostat, the On/Off Switch must be left "ON". Turning the On/Off Switch "OFF" will keep the heater off always. Travis Industries 4041028 100-01151 Operation 23 Starting The Pilot Flame The pilot flame is required to ignite the main burners (it also plays a safety role). It should be left on once lit. It will stay lit unless the gas control valve is turned to "OFF". However, the pilot will go out if the gas is shut off, the propane tank runs out (or low) or if the stove malfunctions. If the pilot turns off frequently, call your dealer for information. To start the pilot follow the directions below: WARNING: When lighting or re-lighting the pilot, the glass must be removed (see page 17). 5 minutes b a Remove the glass (see page 17 for details). b Push the gas control knob in slightly and turn it to the "OFF" position. The knob will not turn from "ON" to "OFF" unless the knob is depressed slightly. Wait five minutes to let any gas that may have accumulated inside the firebox escape. If you smell leaking gas, follow the directions on the cover "IF YOU SMELL GAS". c a Turn the gas control knob to the "PILOT" position and press the knob in, this will allow gas to flow to the pilot light. Press the button on the pilot igniter repeatedly until you see the pilot light. WARNING: If the pilot does not light after 15 seconds, release the knob and call your dealer for service. Do not attempt to light pilot until service has been performed. AA AA AA AA AA PILOT IGNITER c 30 seconds AA AAA A AA AA d ? e NOTE: You may wish to remove the log set to gain a better view of the pilot (see page 19). d Keep the gas control knob depressed for 30 seconds once it is lit. e Release the gas control knob. If the pilot goes out, repeat step C. If the pilot refuses to stay lit, call your dealer for service. With the pilot lit, proceed to step “f”. f Replace the glass. g Turn the gas control knob counter-clockwise to "ON". The pilot is now lit and the heater can be turned on and off. Travis Industries f g 4041028 100-01151 Operation 24 Starting the Heater for the First Time + Burn the heater at a medium setting for approximately one hour the first time. This will cure the painted surfaces. Fumes from the paint curing and oil burning off the steel may occur. This is normal. We recommend you open the window to vent the room. + Condensation may appear on the glass each time you start the Heater - this is normal. + Blue Flames will occur on the heater when it first comes on. After fifteen minutes the flames will turn a more realistic yellow and orange color. • Certain installations use a remote "wall switch" to turn the heater on and off. If this is the case, leave the ON/OFF switch "ON". Turning the Heater On and Off After the pilot has been started... See the instructions included with the remote for details on operation. °F See the instructions included with the remote for changing the battery. Use this switch to turn the main burner on and off manually. Au t o Ca Tim nc e el Tim Se e t OM TE OF MP F F RO OF MIN SE T TE MP TIM ER °F ON For systems with wall thermostats, use this switch to control the temperature (right is hotter, left cooler). Some systems require the on/off switch to be on. EXTINCTION POPS- It is not uncommon to have a small "pop" moments after shutting the heater off (and in some cases, on). This is more common on LP heaters. If you are concerned, contact your dealer for evaluation. ! Do not place any combustible items on top of or directly in front of the heater, even temporarily. The optional thermostat may start the heater causing a combustible item to ignite. • If the heater turns on and off frequently while using the thermostat, you may want to adjust the flame height down until it produces just enough heat needed. Adjusting the Flame Height + Your heater has an adjustable flame to tailor the look and heat output to your specific needs. It is adjusted by turning the “HI – LO” dial on the gas control valve. Flame Height Adjustment Knob Index Mark Turn counter-clockwise to adjust the flame higher, clockwise to lower. Travis Industries 4041028 100-01151 Operation 25 Adjusting the Blower Speed The internal blower helps transfer the heat from the heater into the room. It will not turn on until the heater is up to temperature (approximately 10 minutes after starting). See the illustration below for instructions on adjusting the blower speed. OFF HI LO BLOWER CONTROL Blower Knob Turn the knob all the way counter-clockwise to turn the blower off. One click clockwise turns the blower to high speed. Turning the knob clockwise from the high position decreases the speed of the blower. Normal Operating Sounds Blower This heater uses a blower to push heated air into the room. You will hear the sound of air movement that increases as the speed is increased. Pilot Flame The pilot flame, which remains on, makes a very slight "whisper" sound. The appliance will creak with change of temperature. Extinction Pops It is not unusual, especially on Propane (LP) appliances, to experience a "pop" when the burner is shut off. Gas Control Valve As the gas control valve is turned on and off you will hear a dull clicking sound. This is the valve opening up and shutting down. Blower Snap Disk This part can produce a clicking sound as it turns the blower on and off. Normal Operating Odors This appliance has several areas that reach high temperatures. Dust or other particles on these areas may burn and create an odor. This is normal during start-up. You may notice the smell is more acute if the appliance was left idle for a long period. Travis Industries 4041028 100-01151 Maintenance 26 Maintaining Your Heater's Appearance ! Fingerprints or other marks left on the optional gold or nickel surface may become etched in place if they are not wiped clean prior to turning the stove on. Clean the gold or nickel with denatured alcohol and a soft cloth (make sure the heater is cool). Other cleaners may leave a film that may become etched into the gold or nickel. Yearly Service Procedure ! Failure to inspect and maintain the heater may lead to improper combustion and a potentially dangerous situation. We recommend the following procedures be done by a qualified technician. 1 Check the pilot flame. It should touch approximately 3/8" of the top of the thermopile and touch the top of the thermocouple (see illustration below). If it does not, contact your dealer for service. 2 Shut off gas to the heater by turning the gas control knob to "OFF" (see step A under "Starting the Pilot" on page 23). Let the heater cool for 15 minutes. Remove the faceplate (see instructions included with face) and glass (see page 17). 3 Remove the log set (NOTE: the logs are very fragile - see page 19). If severely deteriorated, replace. Check the logs for sooting. A small amount of soot along the bottom of the logs is normal. If excessive sooting is found, the heater will require adjustment. Contact your dealer. 4 Clean the burner (especially the burner holes) and inspect the following: • • Check the burner for cracks, deterioration, or warping Check the firebox and area around the pilot to make sure there is no warping or damage. If any problem is found, discontinue use and contact your dealer for service. Check the walls and ceiling of the firebox for deterioration. Check the Before Disassembly - Check burner the pilot flame. It should touch holes. the thermocouple and thermopile. AA AAA AAA AA AAA AAA AA AAA AAA AAA AAA AAA Make sure the burner Thermopile Pilot Hood Thermocouple is not warped or damaged. 5 Replace the log set. Replace the glass. Make sure the gasket along the perimeter of the glass contacts the face of the firebox and forms an air-tight seal. If it does not, re-align. If the glass or glass frame is damaged, replace it. 6 Inspect behind the access door. Clean if necessary. Check the gas control valve and gas lines. If damage is found, discontinue use and contact dealer for service. Clean the air channels and ducts. 7 Start the pilot and turn on the main burner. The flames should be orange/yellow and not touch the top of the firebox. If the pilot or main burners do not burn correctly, contact your dealer for service. Monitor the blower operation. 8 Remove any debris or vegetation near the vent termination. Contact your dealer if any sooting or deterioration is found near the vent termination. Travis Industries 4041028 100-01151 Maintenance 27 Troubleshooting Table Problem: Pilot Will Not Light Main Burners Will Not Start Remote Control Does Not Work Thermostat Does Not Work Heater Will Not Distribute Heat Possible Cause: Don't Call for Service Until You: A gas shut off valve is turned off Check all gas shut off valves The gas control knob isn't turned to "PILOT" See "Starting the Pilot Light" Step C The valve control knob isn't pushed in See "Starting the Pilot Light" Step C The igniter wasn't pressed repeatedly See "Starting the Pilot Light" Step C No Propane in Tank Check Tank Level The pilot light has gone out See "Starting the Pilot Light" The gas control valve is turned to "PILOT" or "OFF" See "Starting the Pilot Light" The ON/OFF switch is turned to "OFF" Turn the ON/OFF switch to "ON" The remote control is not working correctly See the remote control instructions The thermostat is disconnected or set too low See "Thermostat Operation" The pilot light has gone out See "Starting the Pilot Light" The gas control valve is turned to "PILOT" or "OFF" See "Starting the Pilot Light" The ON/OFF switch is turned to "OFF" Turn the ON/OFF switch to "ON" The remote is too far away from the heater Use the remote closer to the heater The remote control receiver is turned "Off" See the remote control instructions One of the two remote control batteries is dead See the remote control instructions The pilot light has gone out See "Starting the Pilot Light" The gas control valve is turned to "PILOT" or "OFF" See "Starting the Pilot Light" The ON/OFF switch is turned to "OFF" Turn the ON/OFF switch to "ON" The thermostat is set too low See "Thermostat Operation" The heater is not getting electricity Check the breaker switch The heater is not up to temperature See "Operating Your Heater" Pilot Goes Out Once A The gas supply has been shut off Month Or More Keep the gas supply turned on The heater has just been started This is normal - see "Starting the Heater for the First Time" Improper air shutter adjustment Adjust Air Shutter - contact your dealer Flames Are Too Short (Under 6") The flame height may be turned too low Turn the flame height to "HI" See "Adjusting the Flame Height" Thin Layer of Soot Covers the Glass The logs or coals are placed incorrectly See "Log Set Installation and Removal" Flames Are Too Blue Improper air shutter adjustment Adjust Air Shutter - contact your dealer Travis Industries 4041028 100-01151 Maintenance 28 How this Heater Works ! This heater was designed with safety as the primary concern. Many of the components inside this heater are for safety purposes. Therefore, only certified gas service technicians should service this heater. What Turns the Main Burners On and Off When heated, the thermopile generates electricity (a very small amount measured in "Millivolts"). This electricity is used to operate the main burners. The main burners are switched on and off using the electricity generated by the thermopile. The ON/OFF switch, remote control, or thermostat control the circuit to the main burner. MAIN BURNER This heater uses a millivolt system to control its operation (a millivolt is a very small amount of electricity). The thermopile and thermocouple generate electricity when heated by the pilot flame. This electricity is used to operate the gas valve. Without enough electricity, the gas valve will not turn on. That is why when starting the pilot the gas control knob has to be pressed in long enough for the thermocouple to heat up and generate enough electricity. The thermopile provides power for the ON/OFF switch, remote control, or thermostat (see the illustration below). Because the thermopile generates the electricity needed to turn the heater on and off, this heater can be operated when the power is out (although the blower will not run). ON OFF What Prevents Gas Buildup + This appliance utilizes a high-technology gas valve in conjunction with a pilot flame to ensure no gas builds up inside the firebox. + The thermocouple (next to the pilot) senses when the pilot flame is lit. If the pilot flame goes out, this thermocouple no longer generates electricity, causing the gas valve to automatically shut off all gas to the heater, preventing the pilot from spilling gas into the firebox. Pilot Flame The pilot flame is a time-proven component that eliminates the possibility of gas buildup inside the firebox. Gas Valve This high-technology valve automatically shuts off all gas if it does not receive a signal from the thermocouple. If any component is damaged or sensing a malfunction, or if the wiring is damaged, it will shut off all gas. Thermocouple The thermocouple generates a small amount of electricity. If the pilot flame goes out, the gas valve automatically shuts off all gas. Travis Industries External Shut Off Valve This valve is placed on the gas line to shut off gas to the appliance during maintenance procedures. Ceramic Glass The glass in your heater is the most durable glass available. It has been tested to be extremely resistant to breakage from temperature changes. 4041028 100-01151 Maintenance 29 Wiring Diagram Thermocouple Thermopile Piezo Igniter Red AA AA Brown On/Off Switch Copper Co-Axial Wire Orange Red Spark Electrode White Pilot Hood Chassis Ground Blower Motor Black Green White Black Black Black White 120 Volt Grounded A.C. Power Supply White Black Blower Thermodisk Blower Rheostat 120 V. Blower Circuit Replacement Parts List Travis Industries 4041028 100-01151 Safety Label 30 Report No. 028-S-21b-5 Certified for USA DVL Insert Vented Gas Fireplace Heater Tested to: ANSI Z21.88a-2000 “Vented Gas Fireplace Heater” and UL 307b-1995 “Gas Burning Heating Appliances for Manufactured Homes”. This appliance must be installed in accordance with local codes, if any; if none, follow the National Fuel Gas Code, ANSI Z223.1/NFPA 54. Installation in Manufactured or Mobile Homes must conform with Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280. This vented gas fireplace heater is equipped at the factory for use with natural gas. If conversion to propane (LP) is desired, the optional factory conversion kit must be used. This appliance is only for use with the type of gas indicated on the rating plate and may be installed in an aftermarket, permanently located, manufactured (mobile) home where not prohibited by local codes. See owner’s manual for details. This appliance is not convertible for use with other gases, unless a certified kit is used. This vented gas fireplace heater is not for use with air filters. Keep burner and control compartment clean. See installation and operating instructions accompanying appliance. This appliance must be properly connected to a venting system in accordance with the manufacturer’s installation instructions. Use only approved coaxial direct vent system to vent this appliance to the exterior. See owner’s manual for approved brands of venting. WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to the owner’s information manual provided with this appliance. For assistance or additional information consult a qualified installer, service agency or the gas supplier. VENTED GAS FIREPLACE HEATER – NOT FOR USE WITH SOLID FUEL CAUTION: Minimum Inlet Pressure (inches W.C.) ................ Maximum Inlet Pressure (inches W.C.)................ Manifold Pressure on “HI” (inches W.C.) ............ L.P. N.G. 11” 5.5” 13” 7” 10” 3.5” Steady State Efficiency . . . . . . . . . . . . Up to 81% (blowers on) Output Capacity Rating . . . . . . . . . . . Up to 32,400 (blowers on) Faceplate to Mantel (from top of insert face) . . . . . . . 10” (255mm) Faceplate to Front Facing. . . . . . . . . . . . . . . . . . . . . . . 8.5” (215mm) Flue Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Owner’s Manual Minimum Clearances to Combustibles Faceplate to Adjacent Wall . . . . . . . . . . . . . . 6” (155mm) Hearth Extension in Front . . . . . . . . . . . . . . . 12” (305mm) Hearth Extension to Sides of Faceplate . . . . 0” (0mm) N.G. 40,000 24,500 (2) 45 FAN TYPE VENTED CIRCULATOR Blower Electrical Rating: 115 V., 1.5 Amps, 60 Hz, 150 watts L.P. Input Rate on “HI” (BTU/Hr)............. 40,000 Input Rate on “LO” (BTU/Hr) ........... 29,000 Main Burner Orifice (DMS)............... (2) 55 This appliance is equipped for installation at 0-2000 ft. 2004 2005 2006 Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. 0446 (IGN) 4800 Harbour Pointe Blvd. SW Mukilteo, WA 98275 In USA, for altitudes above 2,000 feet, the vent configuration, orifice, or combination of both may need to be changed. See the owner’s manual for information on making these changes. Manufacture Date: 100-01151 4041028 Travis Industries Hot while in operation. Do not touch. Severe burns may result. Keep children, clothing, furniture, gasoline and other liquids having flammable vapors away. Do not operate this appliance with glass removed, cracked or broken. Replacement of the panel(s) should be done by a licensed or qualified service person. The safety (listing) label is on a plate chained to the gas control valve. A copy of the safety label is shown to the right. Limited 7 Year Warranty 31 To register your TRAVIS INDUSTRIES, INC. 7 Year Warranty, complete the enclosed Warranty card and mail it within ten (10) days of the appliance purchase date to: TRAVIS INDUSTRIES, INC., 4800 Harbour Pointe Blvd. SW, Mukilteo, WA 98275. TRAVIS INDUSTRIES, INC. warrants this gas appliance (appliance is defined as the equipment manufactured by Travis Industries, Inc.) to be defect-free in material and workmanship to the original purchaser from the date of purchase as follows: Check with your dealer in advance for any costs to you when arranging a warranty call. Mileage or service charges are not covered by this warranty. This charge can vary from store to store. Years 1 & 2 - COVERAGE: PARTS & LABOR Burner Assembly: Gas Control Assembly Accessories Burner, Air Shutter Assembly, Main Burner Orifice Firebox Assembly: Adjustable control valve, millivolt wiring and connectors (located within the appliance), thermopile, thermocouple, pilot hood, orifices, pilot gas line, piezo ignitor Cast Fireback, Panels, Faceplate (see “Conditions and Exclusions” # 9) Adjustable Air Restrictor, Pressure Relief Mechanisms, Glass Frame and Latch Ceramic Glass Electrical Assembly: Wiring harness, snap discs, Blower, Blower Rheostat Glass (breakage from thermal shock) Ceramic Logs Log Set, Coals, Ember Strip (Steel Fiber) Exclusions: Convection Heat Exchanger Re-Installation Allowance One-Way Freight Allowance Paint, Gasketing Years 3 THROUGH 5 - COVERAGE: PARTS & LABOR Firebox Assembly: Convection Heat Exchanger Adjustable Air Restrictor, Pressure Relief Mechanisms, Glass Frame and Latch One-Way Freight Allowance Exclusions: Paint, Gasketing, Burner Assembly, Electrical Assembly, Gas Control Assembly, Ceramic Glass, Ceramic Logs, Accessories (Fireback, Panels, Faceplate), Re-Installation Allowance Years 6 & 7 - COVERAGE: PARTS ONLY Firebox Assembly: Adjustable Air Restrictor, Pressure Relief Mechanisms, Glass Frame and Latch Exclusions: Paint, Gasketing, Burner Assembly, Electrical Assembly, Gas Control Assembly, Ceramic Glass, Ceramic Logs, Convection Heat Exchanger, Accessories (Fireback, Panels, Faceplate), Re-Installation Allowance, One-Way Freight Allowance, Labor CONDITIONS & EXCLUSIONS 1. This new gas appliance must be installed by a qualified gas appliance technician. It must be installed, operated, and maintained at all times in accordance with the instructions in the Owner’s Manual. Any alteration, willful abuse, accident, neglect, or misuse of the product shall nullify this warranty. 2. This warranty is nontransferable, and is made to the ORIGINAL purchaser, provided that the purchase was made through an authorized TRAVIS dealer. 3. Discoloration and some minor expansion, contraction, or movement of certain parts and resulting noise, is normal and not a defect and, therefore, not covered under warranty. The installer must ensure the appliance is burning as per the rating tag at the time of installation. Over-firing (operation above the listed BTU rate) of this appliance can cause serious damage and will nullify this warranty. 4. The warranty, as outlined within this document, does not apply to the chimney components or other Non-Travis accessories used in conjunction with the installation of this product. If in doubt as to the extent of this warranty, contact your authorized TRAVIS retailer before installation. 5. Travis Industries will not be responsible for inadequate performance caused by environmental conditions such as nearby trees, buildings, roof tops, wind, hills or mountains or negative pressure or other influences from mechanical systems such as furnaces, fans, clothes dryers, etc. 6. This Warranty is void if: a. The unit has been operated in atmospheres contaminated by chlorine, fluorine or other damaging chemicals. b. The unit is subject to submersion in water or prolonged periods of dampness or condensation. c. Any damage to the unit, combustion chamber, heat exchanger or other components due to water, or weather damage which is the result of, but not limited to, improper chimney/venting installation. 7. Exclusions to this 7 Year Warranty include: injury, loss of use, damage, failure to function due to accident, negligence, misuse, improper installation, alteration or adjustment of the manufacturer's settings of components, lack of proper and regular maintenance, damage incurred while the appliance is in transit, alteration, or act of God. 8. This 7 Year warranty excludes damage caused by normal wear and tear, such as paint discoloration or chipping, worn or torn gasketing, corroded or cracked logs, embers, etc. Also excluded is damage to the unit caused by abuse, improper installation, modification of the unit, drilling of the orifices, or the use of fuel other than that for which the unit is configured. Units are shipped for natural gas and must be converted to propane using the included conversion kit. Confirm fuel configuration with your installer. 9. Damage to gold or nickel surfaces caused by fingerprints, scratches, melted items, or other external sources left on the gold or nickel from the use of cleaners other than denatured alcohol is not covered in this warranty. 10. TRAVIS INDUSTRIES, INC. is free of liability for any damages caused by the appliance, as well as inconvenience expenses and materials. Incidental or consequential damages are not covered by this warranty. In some states, the exclusion of incidental or consequential damage may not apply. 11. This warranty does not cover any loss or damage incurred by the use or removal of any component or apparatus to or from the TRAVIS gas appliance without the express written permission of TRAVIS INDUSTRIES, INC. and bearing a TRAVIS INDUSTRIES, INC. label of approval. 12. Any statement or representation of TRAVIS products and their performance contained in TRAVIS advertising, packaging literature, or printed material is not part of this 7 year warranty. 13. This warranty is automatically voided if the appliance’s serial number has been removed or altered in any way. If the appliance is used for commercial purposes, it is excluded from this warranty. 14. No dealer, distributor, or similar person has the authority to represent or warrant TRAVIS products beyond the terms contained within this warranty. TRAVIS INDUSTRIES, INC. assumes no liability for such warranties or representations. 15. Travis Industries will not cover the cost of the removal or re-installation of hearths, venting or other components. 16. If for any reason any section of this warranty is declared invalid, the balance of the warranty remains in effect and all other clauses shall remain in effect. 17. This 7 year warranty is the only warranty supplied by Travis Industries, Inc., The manufacturer of the appliance. All other warranties, whether express or implied, are hereby expressly disclaimed and purchaser’s recourse is expressly limited to the warranties set forth herein. IF WARRANTY SERVICE IS NEEDED: 1. 2. 3. 4. If you discover a problem that you believe is covered by this warranty, you MUST REPORT it to your TRAVIS dealer WITHIN 30 DAYS, giving them proof of purchase, the purchase date, and the model name and serial number. Travis Industries has the option of either repairing or replacing the defective component. If your dealer is unable to repair your appliance’s defect, he may process a warranty claim through TRAVIS INDUSTRIES, INC., including the name of the dealership where you purchased the appliance, a copy of your receipt showing the date of the appliance’s purchase, and the serial number on your appliance. At that time, you may be asked to ship your appliance, freight charges prepaid, to TRAVIS INDUSTRIES, INC. TRAVIS INDUSTRIES, INC., at its option, will repair or replace, free of charge, your TRAVIS appliance if it is found to be defective in material or workmanship within the time frame stated within this 7 year warranty. TRAVIS INDUSTRIES, INC. will return your appliance, freight charges (years 1 to 5) prepaid by TRAVIS INDUSTRIES, INC., to your regional distributor, or dealership. Check with your dealer in advance for any costs to you when arranging a warranty call. Mileage or service charges are not covered by this warranty. This charge can vary from store to store. Travis Industries 4041028 100-01151 Optional Equipment 32 LP Conversion Instructions Install the conversion kit prior to installing the gas line to ensure proper gas use. 1 2 Remove the glass (see page 17). Remove the logs, coals, and ember strips (if installed page 19) Remove the burner (see illustration below). A AA AAA AA Remove the ember shelfs. Note: when in place, there is a gap between the shelf and the burner. b Lift slightly on the burner and slide it to the left so the mixing tubes slide off the orifices. a Slide both air shutters all the way to the right. AA AA AA Make sure this pin inserts into the hole in the bottom of the burner when re-installing. Follow the directions below to install the LP (propane) orifices. Slide the air shutters to provide better access to the orifices. Use a 1/2” open end wrench to unscrew the burner orifices. The LP orifices have “55” stamped on them. Apply thread sealant to the new orifice and install. 45 1/2" Wrench 55 3 5/16” Travis Industries The NG orifices have “45” stamped on them. NOTE: Screw the LP orifice in so the orifice shoulder protrudes 5/16” (indicating full insertion). 4041028 100-01151 Optional Equipment 4 33 Remove the pilot orifice following the instructions below. Replace with the propane pilot orifice a Lift the pilot hood c Remove the orifice and replace with the LP orifice. Screw the orifice all the way in and replace the pilot hood. off the pilot assembly. Orifice Identification: LP (Propane) Orifice b 35 Use a hex wrench to 35 unscrew the orifice. NG (Natural Gas) Orifice 62 5/32" Hex NOTE: when re-attaching, this pin lines up with the notch in the pilot hood. 5 6 Install the logs and embers. a Remove and discard the three screws using a slotted screwdriver of Torx T-20. Replace glass and face. Slotted Screwdriver (or T-20 Torx) 7 Remove the regulator from the front of the gas control valve. Replace with the propane regulator, using the new gasket and screws included with the regulator. NOTE: Leak test this area after the heater is installed, gas is connected, and the main burner is lit. c Install the LP regulator. Use the screws included with the LP regulator. Tighten to approximately 25 Lbs. torque. Slotted Screwdriver (or T-20 Torx) 8 Make the gas line connection, bleed the gas line (if applicable), start the heater and thoroughly leak-test all gas connections and the gas control valve. Check the pilot. Adjust if necessary. WARNING: NOTE: Make sure the regulator gasket is correctly aligned before installation. d Place the LP label on the base near the gas control valve. When lighting or re-lighting the pilot, the glass must be removed (see page 17). The pilot flame must contact the thermocouple and To adjust the pilot flame, turn this screw. Clockwise thermopile (see the illustration below). Adjust the pilot up or lowers the flame while counter-clockwise raises it. Standard Screwdriver Travis Industries b Remove and discard the regulator, diaphram, spring and center post. 4041028 down as necessary. 100-01151 Optional Equipment 34 Cast Aluminum Firebacks ! (Brick Pattern 98500737, Classic Pattern 98500743) Turn the gas control valve to "OFF" prior to conducting any service. 1 Attach the lower brick retainers following the directions below. Lower Brick Retainer A AA A AA AAA Remove the ember shelfs. Attach the lower brick retainers to the ember shelf with the included screws. 2 Remove the baffle at the top of the firebox following the directions below. Baffle 7/16" Wrench Loosen the two bolts at the back of the firebox. Lift the baffle up to remove it. Travis Industries 4041028 100-01151 Optional Equipment 3 35 Install the firebacks following the directions below. d Secure the upper rear fireback by installing the upper rear fireback clip over the bolts (do not tighten the bolts until the baffle is replaced). c Rest the upper rear fireback on top of the rear fireback brace. b Slide the rear fireback brace over the lower rear fireback (note how the joggle tilts forward). Place them against the back wall of the firebox and attach with the screw removed in step a. a Remove the screw on the back wall of the firebox. 5/16" Nutdriver The rear fireback rests on this ledge at the rear of the firebox. e Side Fireback Clip Remove the screws on both side walls of the firebox. Make sure the notches on the side firebacks fit into the grooves on the firebox floor. f Secure the side firebacks by attaching the fireback clips to the firebox with the screws removed in step “e”. 4 Replace the baffle removed in step 2. Travis Industries 4041028 100-01151 Optional Equipment 36 Ceramic Firebacks (Part # 98500638) ! Turn the gas control valve to "OFF" prior to conducting any service. 1 Remove the baffle at the top of the firebox following the directions below. Baffle 7/16" Wrench Loosen the two bolts at the back of the firebox. Lift the baffle up to remove it. Travis Industries 4041028 100-01151 Optional Equipment 2 37 Install the firebacks following the directions below. Remove the screws on both side walls of the firebox. a b Place the lower rear fireback on the ledge on the rear wall of the firebox. c AA AAA AAAA AAA AA AAA AA AAA AAA Rest the upper rear fireback on top of the lower rear fireback and hold in place. The rear fireback rests on this ledge at the rear of the firebox. e d Attach the clips (included with insert) to secure the side firebacks (use the screws removed in step “a”) . Slide the side firebacks into place, pinning the rear fireback in place. AA AAAA AAA AAA AAA AAA AA AA AAA AAA AAA AAA AAA Ember Shelf f 3 Place the floor fireback on the ember shelfs. Ember Shelf Replace the baffle removed in step 1. Travis Industries 4041028 100-01151 Index 38 Approved Vent Configurations..........................12 Adjusting the Blower Speed..............................25 Adjusting the Flame Height ...............................24 Air Shutter Adjustment......................................21 Altitude Considerations.....................................11 Blower Control..................................................25 BTU Input.........................................................6 BTU Output......................................................6 Cap (see vent installation)..................................12 Chimney Cap (see vent installation)....................12 Chimney Installation (see vent installation)..........12 Clearances.......................................................9 Condensation on Glass.....................................24 Dimensions......................................................6 Dura-Vent (part numbers)..................................12 Electrical Connection........................................16 Face Dimensions (see chart under “Clearances”)9 Face Installation (see instructions included w/ face) Facing Requirements (see “Insert Clearances”) ..9 Finalizing the Installation....................................17 Floor Protection (Hearth)...................................8 Fuel.................................................................4 Gas Control Valve (Location)..............................22 Gas Inlet Pressure.............................................10 Gas Line Connection ........................................10 Gas Line Install..................................................10 Gas Smell.................................See Inst. on Cover Glass Installation and Removal ...........................17 Hearth Requirements........................................8 Heating Specifications ......................................6 How this Heater Works ......................................28 Travis Industries Installation Options ...........................................6 Items Required for Installation............................7 Leaking Gas .............................See Inst. on Cover Listing Information ............................................30 Location of Controls..........................................22 Log Set Installation and Removal .......................19 Maintenance ....................................................26 Mantel Requirements........................................9 Maximum Vent Length......................................11 Noise (see Normal Operating Sounds) ...............25 Normal Operating Sounds.................................25 Packing List......................................................7 Pilot Flame Inspection.......................................20 Piping Installation (see Gas Line Install)...............10 Remote Control Operation ................................24 Safety Label.....................................................30 Safety Precautions ...........................................4 Starting The Pilot..............................................23 Starting the Heater for the First Time ..................24 Thermostat Operation.......................................24 Turning the Heater On and Off...........................24 Vent Length.....................................................12 Vent Part Numbers ...........................................12 Vent Requirements ..........................................11 Warnings..........................................................4 Warranty...........................................................31 Water on Glass (see Condensation) ...................24 What Prevents Gas Buildup...............................28 What Turns the Main Burners On and Off............24 Wiring Diagram..................................................29 Yearly Service Procedure..................................26 4041028 100-01151